Modular component connector

Abstract

 A modular component connector (18) for joining modular components together includes a female member (22), a male member (20), and an annular member (24). The female member (22) defines a first elongated bore (40) and a second elongated bore (42). The male member (21) has a first elongated portion (30) and a second elongated portion (32) axially extending therefrom. The first elongated portion (30) provides a first positive contact point (94) with the first elongated bore (40) of the female member (22). The annular member (24) includes an internal sidewall (56) and an external sidewall (58). The internal sidewall (56) slidably engages the second elongated portion (32) of the male member (20) and the external sidewall (58) slidably engages the second elongated bore (42) of the female member (22). Upon the annular member (24) slidably engaging the male and female members (20, 22), the annular member (24) establishes a second positive contact point (96) between the second elongated portion (32) of the male member (20) and the second elongated bore (42) of the female member (22).

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] This invention relates generally to a modular component connector for joining modular components together and, more particularly, to a modular component connecter for coupling together modular components of a knee, hip or shoulder prosthesis for use in orthopedic surgery.

2. Discussion of the Related Art

[0002] Various modular prosthetic devices are currently known and utilized during orthopedic surgeries. These modular prosthetic devices include modular knee, hip and shoulder prosthesis. Since the modular prostheses consist of multiple components, various coupling mechanisms are used to secure or couple the modular components together.

[0003] One of the primary and most common coupling mechanisms employed consists of a Morse type taper 10, shown in Fig. 1. The Morse type taper 10 is generally known as a "self-holding" or "self-locking" taper because the angle of the conical taper is generally 2° to 4° which creates considerable friction to lock a male portion 12 into a female portion 14.

[0004] However, because of tolerance effects during manufacturing of the Morse type taper 10, it is very difficult to manufacture the male portion 12 and the female portion 14, so that the male portion 12 axially engages along the entire female portion 14. Accordingly, in some instances the male portion 12 may only contact the female portion 14 at one contact point at an unknown location within the Morse type taper 10, as shown by reference numeral 16. This single contact point 16 occurs because in some instances the conical angle of the male portion 12 does not mate with the conical angle of the female portion 14. This condition may in turn allow for micro-motion to occur between the components resulting in fretting at the contact point 16. Such fretting may eventually lead to stress fractures along the loaded contact point 16 that could result in catastrophic failure of the connector.

[0005] Other taper connections, such as those disclosed in U.S. Patent No. 4,917,530 to Englehardt et al. are designed to preclude contact between the male tapered member and the peripheral edge defining the mouth of the bore in the female member. However, Englehardt et al. does not address the problem of having only one contact point between the male and female portions at a location that may vary within the bore, thereby permitting micro motion. Rather, Englehardt et al. assumes axial contact, that is, full face to face contact of the adjacent tapered surfaces of the male portion and female bore and is only concerned with impingement at the mouth of the female bore. Therefore, Englehardt et al does not reduce micro motion caused by practical tolerance effects or the potential resulting stress fractures associated therewith.

[0006] Other connection mechanisms have also utilized ion implantation along the connection members to provide an ion layer in these areas. However, ion implantation does not appear to provide any appreciable increase in strength because the surface thickness of the implanted ion layer is only generally a few microns thick. Alternatively, mechanical hardening techniques have not even been considered, nor utilized because of the tight tolerance effects of such connections and the inability to perform such mechanical hardening with such tight tolerance effects.

[0007] What is needed then is a modular component connector for a modular knee, hip or shoulder prosthesis which does not suffer from the above-mentioned disadvantages. This in turn, will provide a modular component connector that substantially reduces or eliminates micro-motion, reduces the possibility of stress fractures, provides positive contact along at least two predictably located separated contact points for increased stability, provides a mechanically hardened surface at least along one contact point to provide a thick surface hardening and a stronger connection, and provides a cost effective and easily manufacturable modular component connector. It is, therefore, an object of the present invention to provide such a modular component connector for use with modular prosthetic devices.

SUMMARY OF THE INVENTION

[0008] In accordance with the teachings of the present invention, a modular component connector for joining modular components together is disclosed. The modular component connector establishes first and second positive contact points along the modular component connector that provides a substantially stable connection between the modular components. This is basically achieved by utilizing a male member which engages a female member along the first and second positive contact points. Moreover, the first positive contact point includes a mechanically hardened surface to further provide for increased strength.

[0009] In one preferred embodiment, a modular component connector for joining modular components together includes a female member which defines a first elongated bore and a second elongated bore. The modular component connector further includes a male member having a first elongated portion and a second elongated portion axially extending therefrom. The first elongated portion of the male member provides a first positive contact point with the first elongated bore of the female member. The modular component connector further includes an annular member having an internal sidewall and an external sidewall. The internal sidewall slidably engages the second elongated portion of the male member and the external sidewall slidably engages the second elongated bore of the female member. Upon slidably engaging the annular member with the male and female members, the annular member establishes a second positive contact point between the second elongated portion of the male member and the second elongated bore of the female member.

[0010] Use of the present invention provides a modular component connector for joining modular components together. As a result, the aforementioned disadvantages associated with the currently available methods and techniques for joining modular components together have been substantially reduced or eliminated.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Still other advantages of the present invention will become apparent to those skilled in the art after reading the following specification and by reference to the drawings in which:

Fig. 1 is a cross-sectional view of a prior art Morse type taper;

Fig. 2 is an exploded perspective view of a modular component connector according to the teachings of a first preferred embodiment of the present invention;

Fig. 3 is an assembled cross-sectional view of the modular component connector shown in Fig. 2 taken along line 3-3 of Fig. 2;

Fig. 4A is a cross-sectional view of a ferrule according to the teachings of a second preferred embodiment of the present invention;

Fig. 4B is a cross-sectional view of a bolt according to the teachings of a second preferred embodiment of the present invention;

Figs. 5A-5C illustrate a method for forming a modular component connector according to the teachings of the first preferred embodiment of the present invention; and

Fig. 6 is a cross-sectional view of a modular knee prosthesis which incorporates the modular component connector according to the teachings of the first preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0012] The following description of the preferred embodiments concerning a modular component connector for coupling modular components of a knee, hip or shoulder prosthesis for use in orthopedic surgery are merely exemplary in nature and are in no way intended to limit the invention or its application or uses. Moreover, while the present invention is described in detail below with reference to coupling modular components of a knee, hip or shoulder prosthesis for use in orthopedic surgery, it will be appreciated by those skilled in the art that the present invention is clearly not limited to only these types of prosthetic devices for orthopedic surgery and may be utilized with various other orthopedic implants, as well as with any other type of device requiring connection of various modular components.

[0013] Referring to Figs. 2-3, a modular component connector 18 according to a first preferred embodiment of the present invention is shown. The modular component connector 18 includes a male member 20, a female member 22, a ferrule 24, a thrust washer 26 and a bolt 28. The components of the modular component connector 18 are preferably made from suitable biocompatible material such as titanium, stainless steel, titanium alloys, cobalt-chrome-molybedenum alloys etc.

[0014] The male member 20, which includes the ferrule 24, is preferably made from titanium and includes a first elongated portion 30 and a second elongated portion 32. The first elongated portion 30 has a toroidal or bulbous external surface 34 having a radial engagement or contact surface. The radial external surface 34 is mechanically hardened by cold working, further described herein, which increases the load strength of the final construction by as much as 25%. The second elongated portion 32 is concentric with and axially extends from the first elongated portion 30. The second elongated portion 32 includes an external cylindrical surface 36 having a radial engagement or contact surface and a threaded internal bore 38. Located at the end of the second elongated portion 32 and concentric therewith is a lead-in step or notch 39.

[0015] The female member 22 is preferably made from titanium and defines an elongated bore having a first elongated frustoconical bore 40 adjacent and concentric with a second elongated reverse frustoconical bore 42. The first elongated bore 40 includes an entrance opening 44 tapering to a smaller exit opening 46 at an angle of about four (4°) degrees inclusive or about two (2°) degrees per side. The second elongated bore 42 has an entrance opening 48 coupled to the exit opening 46. The entrance opening 48 tapers to a larger exit opening 50 at an angle of about twenty (20°) degrees inclusive or about ten (10°) degrees per side. The taper in the first elongated bore 40 is opposite or reverse of the taper in the second elongated bore 42. Concentric with the first elongated bore 40 and the second elongated bore 42 is a third elongated cylindrical bore 52 forming a ledge 54 at the exit opening 50 which is an access port for the bolt 28.

[0016] The ferrule 24 preferably consists of a soft commercially pure titanium alloy annular member having an internal cylindrical sidewall 56 and an external conical sidewall 58. The internal cylindrical sidewall 56 is formed to slidably and radially engage the external cylindrical surface 36 of the male member 20, while the external conical sidewall 58 having a radial engagement or contact surface is formed to slidably and radially engage the second elongated frustoconical bore 42 of the female member 22. The ferrule 24 is a deformable annular member which is operable to deform upon the internal cylindrical sidewall 56 and the external conical sidewall 58 slidably engaging the male member 20 and the female member 22, further discussed herein.

[0017] The thrust washer 26 is preferably made of cobalt-chrome-molybedenum and includes an internal cylindrical sidewall 60, an external cylindrical sidewall 62, a first annular surface 64 and a second annular surface 66. The internal cylindrical sidewall 60 slidably engages the external cylindrical surface 36 of the male member 20, while the second annular surface 66 engages an annular surface 68 of the ferrule 24. The external cylindrical sidewall 62 is of a diameter sufficient to allow the ferrule 24 to deformably engage the male member 20 and the female member 22 as the ferrule 24 is slidably engaged along the external cylindrical surface 36.

[0018] The bolt 28 is preferably made of titanium and includes a head 70 and a threaded shaft 72 that threadably engages the threaded bore 38 in the male member 20. The head 70 includes a hex drive 74 or other suitable drive. The head 70 includes a circular planar underside 76 which engages the first annular surface 64 of the thrust washer 26.

[0019] Turning to Fig. 4A, a second preferred embodiment of the ferrule 24 is shown. In this regard, like reference numerals will be used to identify similar structures as described with respect to the first preferred embodiment of the ferrule 24. The ferrule 24, shown in Fig. 4A, is to be used in place of utilizing a thrust washer 26. The ferrule 24 includes the internal cylindrical sidewall 56 and the external conical sidewall 58 as with the first preferred embodiment. The ferrule 24 of the second preferred embodiment also includes an annular collar 78 used in place of the thrust washer 26 having an internal cylindrical sidewall 80 and an external cylindrical sidewall 82, each being concentric with the internal cylindrical sidewall 56. The collar 78 also includes an annular surface 84 which is operable to be engaged by the underside 76 of the head 70. By providing an internal cylindrical sidewall 80 having a diameter larger than the internal cylindrical sidewall 56 and an external cylindrical sidewall 82 having a diameter smaller than the largest diameter portion of the external conical sidewall 58, the collar 78 will not bind upon deformably radially engaging the ferrule 24 with the male member 20 and the female member 22.

[0020] Turning to Fig. 4B, a second preferred embodiment of the bolt 28 is shown. In this regard, like reference numerals will be used to identify similar structures as described with respect to the first preferred embodiment of the bolt 28. Here again, the bolt 28, as shown in Fig. 4B, is configured to be utilized in place of using a thrust washer 26. The bolt 28 includes the head 70 and the threaded shaft 72. Positioned at the underside 76 of the head 70, is an annular collar 86. The annular collar 86, has an internal cylindrical sidewall 88 and an external cylindrical sidewall 90 forming an annular surface 92 therebetween. The internal cylindrical slidewall 88 is of a larger diameter than the external cylindrical surface 36, while the diameter of the external cylindrical slidewall 90 is smaller than the largest diameter portion of the external conical sidewall 58. This enables the annular surface 92 to engage the annular surface 68 of the ferrule 24 without binding on the male member 20 or the female member 22. It should also be noted that the thrust washer 26 may simply be eliminated by using an appropriately sized ferrule 24 and the first preferred embodiment of the bolt 28.

[0021] Referring back to Fig. 3, the operation of assembling the modular component connector will now be described. First, it is to be understood that the modular component connector 18 may be utilized with various modular orthopedic implants such as knee, hip or shoulder prosthesis, as well as with any other device having modular components which require joining or coupling of the modular components. For example, the male member 20 may form a part of a stem for a modular hip prosthesis, while the female member 22 may form the proximal portion of the modular hip prosthesis. The male member 20 is first inserted into the female member 22 such that the first elongated portion 30 just radially engages the first elongated bore 40 at the mechanically hardened toroidal or bulbous external surface 34. This radial engagement creates a first positive contact point 94 at a substantially predetermined known location situated at one end of the modular component connector 18.

[0022] The ferrule 24 is then passed through the cylindrical third bore 52 and over the notch 39 until the internal cylindrical sidewall 56 slidably engages the external cylindrical surface 36. As the internal cylindrical sidewall 56 engages the external cylindrical surface 36, the external conical sidewall 58 slidably and radially engages the second elongated frustoconical bore 42 of the female member 22. The thrust washer 26 is then passed through the cylindrical third bore 52 and positioned atop the ferrule 24 such that the second annular surface 66 of the thrust washer 26 engages the annular surface 68 of the ferrule 24. The bolt 28 is finally passed through the cylindrical third bore 52 with the shaft 72 being threadably received within the threaded bore 38 of the male member 20.

[0023] The male member 20 may then be struck to fully seat the male member 20 within the female member 22. Upon tightening the bolt 28, the underside 76 of the head 70 forces the thrust washer 26 into engagement with the ferrule 24, while the ferrule 24 deformably engages about the external cylindrical surface 36 and radially within the elongated frustoconical bore 42. This simultaneously provides the first positive contact point 94 at a first position and a second positive contact point 96 at a second position. The first positive contact point 94 establishes a substantially annular or radial contact surface substantially 360° around the mechanically hardened bulbous surface 34 between the bulbous surface 34 and the first elongated bore 40. The second positive contact point 96 establishes a substantially annular or radial contact surface substantially 360° around where the ferrule 24 deformably engages both the cylindrical surface 36 of the male member 20 and the second elongated frustoconical bore 42 of the female member 22.

[0024] The spaced apart or displaced first positive contact point 94 with the second positive contact point 96, positioned substantially at each end of the modular component connector 18, provides a substantially stable and strong connector 18 which substantially reduces or eliminates any micro motion. Moreover, the primary load bearing site or the first positive contact point 94 includes the mechanically hardened bulbous contact surface 34 that substantially increases the load strength along this contact point 94 by as much as 25%. Still further, it should be noted that the male member 20 does not contact or engage the female member 22 between the spaced apart first and second positive contact points 94 and 96 or before the first positive contact point 94, thereby eliminating any regions that would be prone to fretting and subsequent stress fractures.

[0025] The method of forming the modular component connector 18 will now be described with reference to Figs. 3 and 5A-5C. The female member 22 is formed by boring out the first elongated bore 40, the second elongated bore 42, and the third elongated bore 52 using an appropriate tool such as a CNC boring machine. Once the female member 22 is formed, the first step in forming the male member 20 is to provide a cylindrical titanium piece of stock. This piece of stock is inserted into a conventional precision CNC lathe. Once positioned within the lathe, the first elongated portion 30 and the second elongated portion 32 are formed by axially turning the cylindrical piece of stock and axially drawing a single point cutting member along the stock. The external cylindrical surface 36 is formed slightly oversized and the toroidal bulbous surface 34 is initially formed with a protruding semi-spherical or bulbous hump 98 formed with a radius which varies to yield a radially displaced thickness of between about .002 inches to about .006 inches and an axial width of about .200 inches centered about the first positive contact point 94. The external cylindrical surface 36 and the bulbous external surface 34 having the protruding hump 98 is formed during the same cutting process so that the surfaces 34 and 36 are substantially concentric with one another.

[0026] Once the male member 20 has been shaped as shown in Fig. 5A, the bulbous or toroidal external surface 34 is mechanically surface hardened by cold-working. Specifically, the protruding hump 98 is rolled with two rollers or knurling wheels 100 having a radius of about 3.5 inches at the first positive contact point 94. This rolling or cold-working with the rollers 100 mechanically hardens and shapes the bulbous surface 34 to a sufficient hardened thickness which thereby increases the load strength along the first positive contact point 94 by as much as 25% over a non-mechanically hardened surface. Those skilled in the art would also understand that various other mechanical hardening techniques could also be performed at the bulbous surface 34, such as by shot peening or precision impacting along this area. Mechanical hardening has been found to be particularly successful here because of the thick surface hardening created at the bulbous surface 34.

[0027] The cold-working performed by the rollers 100 displaces excess material 102 from the protruding hump 98 adjacent to the rollers 100 and can distort the external cylindrical surface 36, as shown in Fig. 5B. To remove the excess material 102, the male member 20 is turned again on the precision lathe, thereby removing the excess material 102 and reducing the oversized external cylindrical surface 36 to its proper size, as well as forming the notch 39 into the end of the external cylindrical surface 36. The displaced material 102 is removed by the lathe following the path 104, shown in Fig. 5C, which sufficiently removes the excess material 102, but does not remove the mechanically hardened surface 34 which will be centrally positioned about the first positive contact point 94. The threaded bore 38 is finally formed within the end of the male member 20.

[0028] Turning to Fig. 6, the modular component connector 18 is shown incorporated into a modular knee prosthesis 106. The modular knee prosthesis 106 includes a femoral component 108 and tibial component 110. The tibial component 110 incorporates the male member 20 into an extension 112 and the female member 22 into a tibial base 114. Positioned atop the tibial base 114 is a tibial insert 116.

[0029] During orthopedic surgery, the extension 112 having the appropriate length is selected which includes the male member 20. Once selected, the extension 112 is engaged with the tibial base 114 housing the female member 22. The ferrule 24 is then slidably engaged on the external cylindrical surface 36 between the male member 20 and the female member 22, with the thrust washer 26 engagably positioned atop the ferrule 24. The tibial insert 116 is positioned atop the tibial base 114, and the bolt 28 is passed therethrough and is threadably engaged within the threaded bore 38 to secure the three modular components. Use of the modular component connector 18 can also be incorporated into hip, shoulder or various other orthopedic implants for use during orthopedic surgery or with any other device which requires coupling of modular components.

[0030] The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations can be made therein without departing from the spirit and scope of the invention.

Claims

1. A modular component connector for joining modular components together for use in orthopedic surgery, said modular component connector comprising:

a female member defining an elongated bore; and

a male member having a radial engagement surface operable to be inserted into the elongated bore of said female member, said radial engagement surface including:

(a) a first contact surface for engaging said female member at a first position;

(b) a second contact surface for engaging said female member at a second position, said second contact surface being displaced from said first contact surface so that said male member is substantially free from engagement with said female member between said first contact surface and said second contact surface.

2. The modular component connector as defined in claim 1 wherein said elongated bore of said female member includes a first elongated frustoconical bore and a second elongated frustoconical bore, said first elongated bore having a taper opposite a taper of said second elongated bore.

3. The modular component connector as defined in claim 1 wherein said male member includes a first elongated portion and a second elongated portion axially extending therefrom, said first elongated portion including said first contact surface, said first contact surface including a bulbous portion.

4. The modular component connector as defined in claim 3 wherein said bulbous portion is mechanically hardened.

5. The modular component connector as defined in claim 3 wherein said male member further includes an annular member having an internal sidewall and an external sidewall, said internal sidewall operable to slidably engage said second elongated portion and said external sidewall including said second contact surface.

6. The modular component connector as defined in claim 3 wherein said internal sidewall of said annular member is an internal cylindrical sidewall and said external sidewall of said annular member is a conical external sidewall.

7. A modular component connector for joining modular components together, said modular component connector comprising:

a female member defining a first elongated bore and a second elongated bore;

a male member having a first elongated portion and a second elongated portion axially extending therefrom, said first elongated portion providing a first positive contact point with said first elongated bore; and

an annular member having an internal sidewall and an external sidewall, said internal sidewall operable to slidably engage said second elongated portion of said male member and said external sidewall operable to slidably engage said second elongated bore of said female member, whereby upon slidably engaging said annular member with said male and female members, said annular member establishes a second positive contact point between said second elongated portion of said male member and said second elongated bore of said female member.

8. The modular component connector as defined in claim 7 wherein said first elongated bore is a first elongated frustoconical bore and said second elongated bore is a second elongated frustoconical bore, said first elongated bore having a taper opposite a taper of said second elongated bore.

9. The modular component connector as defined in claim 8 wherein said first elongated portion is a bulbous portion and said second elongated portion is a cylindrical portion.

10. The modular component connector as defined in claim 9 wherein said bulbous portion is mechanically hardened.

11. The modular component connector as defined in claim 9 wherein said internal sidewall is an internal cylindrical sidewall and said external sidewall is a conical external sidewall.

12. The modular component connector as defined in claim 7 whereby upon slidably engaging said annular member with said male and female members, said annular member deformably engages said second elongated portion of said male member and said second elongated bore of said female member to establish said second positive contact point.

13. The modular component connector as defined in claim 12 further comprising a bolt, said bolt operable to slidably deform said annular member as said annular member slidably engages said male and female members.

14. The modular component connector as defined in claim 13 further comprising a thrust washer, said thrust washer operable to be engaged by said bolt to engage said annular member.

15. The modular component connector as defined in claim 13 wherein said annular member includes an annular collar operable to be engaged by said bolt.

16. The modular component connector as defined in claim 7 wherein said modular component connector is operable to simultaneously establish said first positive contact point and said second positive contact point with each positive contact point spaced apart at substantially each end of said modular component connector to provide a substantially stable connection between said male and female members.

17. The modular component connector as defined in claim 7 wherein a portion of said first elongated portion is mechanically hardened by cold-working.

18. A modular component connector for joining modular components together for use in orthopedic surgery, said modular component connector comprising:

a female member defining a first elongated bore; and

a male member having a first elongated portion, said first elongated portion includes a mechanically hardened exterior surface, wherein said mechanically hardened exterior surface of said first elongated portion provides a first positive contact point with said first elongated bore of said female member.

19. The modular component connector as defined in claim 18 wherein said mechanically hardened exterior surface of said first elongated portion is mechanically hardened by cold-working.

20. The modular component connector as defined in claim 19 wherein said mechanically hardened exterior surface of said first elongated portion is a toroidal bulbous surface mechanically hardened by cold-working.

21. The modular component connector as defined in claim 18 wherein said male and said female members are fixedly secured relative to one another at only said first positive contact point and a second positive contact point, each of said contact points being separated and located substantially at each end of said modular component connector.

22. The modular component connector as defined in claim 18 wherein said female member further defines a second elongated bore and said male member further includes a second elongated portion axially extending from said first elongated portion, and wherein said male member further includes an annular member operable to slidably engage said second elongated bore of said female member and said second elongated portion of said male member to establish a second positive contact point between said male and female members.

23. The modular component connector as defined in claim 18 wherein said female member is a portion of a first modular component in an orthopedic implant and said male member is a portion of a second modular component in said orthopedic implant.

24. A method for forming a modular component connector for use in orthopedic surgery, said method comprising the steps of:

forming a male member having a first elongated portion;

mechanically hardening a portion of said first elongated portion of said male member;

forming a female member having a first elongated bore operable to be engaged by said mechanically hardened portion of said first elongated portion; and

engaging said mechanically hardened portion of said first elongated portion of said male member with said first elongated bore of said female member during orthopedic surgery.

25. The method as defined in claim 24 wherein the step of forming the male member having the first elongated portion further includes the step of forming a protruding hump at said first elongated portion, and wherein the step of mechanically hardening the portion of said first elongated portion of said male member further includes the step of cold-working said protruding hump to form a mechanically hardened bulbous surface at said first elongated portion.

26. The method as defined in claim 25 further comprising the step of removing any excess material displaced by forming said hardened bulbous surface of said first elongated portion of said male member.

Drawing